Apparatus for forming mineral wool mats



Oct. 12, 1948. H. T. 0085 ETAL APPARATUS FOR FORMING MINERAL WOOL MATSINVENTORS Filed Sept. 50, 1944 MW. 2 a 1 N, r w 0 T A 2% Patented Oct.12,

UNITED STATES PATENT OFFICE Harold T. Coss, Plalnfleld, and Edward B.Powell,

North Plainfield, N. 3., assignors to Johns-Manville (3orporation, NewYork, N. Y.,.a corporatlon of how York Application September 30, 1944,Serial No. 556,562

12 Claims.

apparatus and method for forming an improved mat or felbmineral wool orsimilar fibers. The term mineral wool is employed herein in a genericsense to include wool or fibers formed from rock, slag, glass-mixturesthereof, and like raw materials.

The invention has for its principal object the provision of an improvedmethod and apparatus for collecting mineral wool fibers coincident withtheir formation and is particularly directed to a method and apparatusfor collecting a thin layer of fibers in a fiber-forming zone anddepositing a plurality of said layer on a receiving member to build upablanket of commercial thickness and width, all as a continuousoperation.- The invention is especially adapted for operation inconjunction with rotor-type fiberizing apparatus? in which moltenmaterial impinges against a rotor driven at high speed and is broken upinto drops or masses which are thrown from the rotor by centrifugalforce and drawn out into fiber or thread form.

Another object of the invention is the provision of a method andapparatus for forming an improved mat or felt of spun mineral fibers.

A further object of the invention is the provision of a method andapparatus for procuring substantially uniform dissemination of a binderor other treating material throughout a felt or mat of the type referredto above,

Briefly stated, the invention in its preferred embodiment resides in amethod and apparatus for collecting fibers, produced by a spinningprocess; substantially immediately after their formation on a rotatabledrum in the form of a thin layer, conveying the layer on the drum to aposition above a conveyor traveling in a direction generally parallel tothe axis of the drum,

and depositing the layer on the conveyor in continuous/folds orlaminations laid laterally of the conveyor. The travel of the conveyoris regulate-d relatively to the rate of removal of the layer from thedrum tobuild up a felt or blanket of the desired thickness. The width ofthe blanket in turn may be determined by controlling the lengths of thefolds or lamin'ations laid across the conveyor. A binder or othertreating ma teriai, where such is desired, is applied to both sides ofthe thin layer prior to its deposition on thcconveyor.

Our invention will be more fully understood and further objects andadvantages thereof will 2 more detailed description thereof which is tofollow and to the accompanying drawings, in

which:

Fig. 1 is a diagrammatic side elevational view, with parts brokenaway'for cleamess of illustration, of an apparatusin accordance with theinvention; and

Fig. 2 is a diagrammatic end elevational view. with parts broken awayand other parts in section, of the apparatus of Fig. 1.

Referring now to the drawings, there i shown an apparatus comprising afiber-forming means including a raw-material-melting furnace it,suitably of I the cupola type, as illustrated. Furnace ID has adischarge trough i2 by which a stream of molten slag, rock, glass, orother fiber-forming material is drawn from the furnace and is dischargedin a position to be contacted by one or more rotors M driven at highspeed by suitable mean (not shown). The molten material striking therotor or rotors is broken up into fine drops, which are thrown out fromthe rotors at high velocity and converted into fibers.

It will be understood that the invention now to be described may beemployed with other fiber-forming means than that described above,although it is particularly adapted for cooperation with the rotor typefiberizing operations.

In accordance with the instant invention, a

drum i6 of relatively large diameter is mounted for rotation in thedirection indicated by the arrow. The drum is located to have a portionof its peripheral surface adjacent to the fiberizins rotors M. Thesurface of the drumis made up of a foraminous material, such asperforated metal, relatively coarse mesh screen, or the like. Metalsheets having perforations approximately one inch in diameter andsubstantially uniformly spaced on 1%." centers have been successfullyemployed to form the drum wall. The drum is supported for rotation in asuitable manner to permit of the inclusion within the drum of a suctionhood and other means to be described. For this purpose the drum as shownincludes a relatively rigid end structure or wall l8 which carries theforaminous peripheral wall 20. The end plate I8 is secured as by element22 to a shaft 24 to rotate therewith. Shaft 24, mounted for rotationwithin bearings 26 of supports 28, is adapted to be driven at high speedby a suitable prime mover or other drive means (not shown) through themedium of a sprocket 30 and chain 32. The construction described above,

become apparent when reference is made to the which supports the drumfrom one end only,

allows, as 'will be readily apparent, the mounting of non-rotatableelements of the apparatus in the drum through the open end thereofopposite plate I 8.

Within drum l5 there.is provided a suction hood 34 connected by means ofa suction main 38 with an air-exhausting device (not shown). The suctionhood, which is supported as by brackets 38, is positioned to draw airthrough a considerable area (hereinafter referred to as the"fiber-receiving area) of the foraminous surface of the drum adjacent tothe fiberizing means l4. The hood 34 is sealed against the rotatingparts to prevent excessive air leakage as by flexible wipers 39.

Fiber-izing means I4 and the fiber-receiving area of the drum arepreferably enclosed by housing 40. The housing aid in controlling theairstream set up by the suction box to confine it to the fiberizingzone. In addition the hood serves as means for collecting unfiberizedparticles.

The means for stripping the layer of fibers formed on drum l8 includes apipe or no'zzle member 42 of a length to extend substantially across thedrum, The inner end of the pipe is closed ofi with a cap, plug, or thelike 44. Member 42 is provided with a plurality of nozzles 48, directedtoward-the adjacent inner surface of the drum, which may comprise holesdrilled through the pipe wall. Pipe 42 is carried by an arm 48, which inturn is connected to a hollow shaft 50. Shaft 50 and arm 48 are suitablycomposed of sections of pipe, the elements 50, 48 and 42 beingconnected, for example, by conventional elbows 52. ,In any event, theseveral elements form a continuous line for conveying a fluid to nozzles46. Hollow shaft 50 is supported as by bracket 54 substantially axiallyof the drum for oscillating movement whereby oscillation of the shaftwill swing pipe 42 through an arc substantially concentric with thesurface of the drum. Hollow shaft 50 is connected through a fluid-tightconnection or gland 53 of any suitable type, with stationary line 51leading from the source of supply (not shown) of the fiuid to bedischarged by nozzles 46.

The means for oscillating shaft 50 is indicated diagrammatically at 56and comprises, for example, an arm 58 fixedly secured to shaft 50 and aconnecting link 60 carrying a follower 62 held in operating engagementas by spring 63 against cam 64. Cam 64 is driven from any suitablesource of power (not shown) in timed relationship to the rotation of thedrum. It will be understood that the invention is not limited to theparticular means shown for oscillating or rocking nozzle member 42through an arc of the required extent, and any other conventional orknown apparatus for imparting similar mechanical movements may beemployed.

A shield comprising a fixed section 5i and a movable section 53 liesclosely adjacent and seals the inner surface of the drum. Section 5iextends from hood 34 to a point adjacent nozzle member 42, when the sameis swung to its further position to the right, as shown by dotted linesin Fig. 1. It is supported in any suitable manner by connecting it tothe hood at one end and securing it at spaced intervals to angle members55 carried by frame members (not shown). Movable section 53 has one endsecured to pipe or nozzle member 42, the other end riding on section 5|.Section 53 is of sufiicient length to overlap section 5i in any positionof pipe 42,

4 Directly below drum ll there is located a conveyor 86 extending in thedirection of the axis of the drum. Conveyor 54 is of foraminouscharacter and is suitably made of wire mesh screen.

The conveyor is driven at a controlled speed, de-

termined by the operation of the other elements of the apparatus,through a suitable drive, not shown in detail, but which may includesupporting roll 68 carried by bearings in brackets ill.

Between the upper and lower reaches of conveyor 88 a suction box 12 islocated to provide a fiow of air through the upper reach of the conveyorbeneath the drum. The suction box is connected by means of a suctionmain 14 with an airexhausting device (not shown). The box may be sealedagainst the under surface of the conveyor by flexible wipers 15.

A housing I. is located between the drum and conveyor 88, the housingsubstantially defining the area of the conveyor on which a fibrous layeris to be deposited from the drum. The housing may be sealed against theconveyor and drum, as by wipers 80. The forward wall I! of the housingis shortened to accommodate a compression roll 84, the roll being spacedfrom the conveyor to define an exit port for the mat. Roll 84 may be adriven or an idler roll, as desired, and is suitably mounted forvertical adjustment to permit changes to be made in the thickness andextent of compaction of the mat or felt.

Means are preferably provided to apply a treating material such as abinder, waterproofing or the like to the thin layer formed on the drum.This mechanism comprises an elongated spray head 86 extending parallelto and substantially across the drum adjacent its outer surface, thehead including a plurality of ports through which the binder or othertreating material issues in the form of fine sprays impinging on thelayer. The spray head is connected to a supply line 88 leading from asuitable supply (not shown). The hinder or other treating material isapplied to v the opposite face of the thin layer preferably by includingthe material in finely divided form in the steam or other fiuid suppliedto nozzle member 42. The treating material may be drawn from thepreviously mentioned or other source of supply and introduced into thesteam line at any suitable point, A binder spray means may also besupported to oscillate with nozzle member 42 to spray binder or othertreating material against the felted layer after it leaves the surfaceof the drum. This means, which may be used either in conjunction with orin substitution for one or both of the other binder applying devices,comprises a spray pipe 80, extending parallel to and substantiallyacross the drum and supported through suitable connections 92 from arm4!, whereby it oscillates with nozzle member 42. An arcuate slot 91 maybe provided in the end wall of housing 82 to accommodate the swingingmovement of pipe 90. The binder or other treating material may be drawnfrom a suitable source of supply, such as that previously mentioned, andconveyed to pipe through a flexible hose or the like 94 and connections92.

In the operation of the apparatus described above, and in carrying outthe method of the instant invention, suction boxes 34 and 12 areconnected through their respective ducts with any desired exhaustingmeans to create a flow of air through the foraminous surface of the drumat the fiber-receiving area and through the surface of the conveyorrespectively. Drum I6 is rotated at a relatively high speed, such as tohave a sur- "lated through the desired are by means of the camarrangement shown. Cam 54 is contoured to move the nozzle member in anarc which will lay the layer in relatively even folds back and forthacross the conveyor.

As the molten material delivered by trough I2 strikes the high speedrotors 14, it is thrown from the rotor by centrifugal force and drawnout into relatively fine threads or fibers. The

fibers are collected on the surface of the drum to form a layer thereonby the inward movement of air through the surface of the drum created bysuction box 34. The speed of rotation of the drum is controlledrelatively to the rate of fiber formation to form a thin layer of thefibers on the drum, say one having a thickness of about inch. It. willbe appreciated that, for purposes of illustration, this layer is shownof exaggerated thickness in the drawing.

The thin lap or layer adheres to the surface of the drum sufficiently tobe carried around to the lower side of the drum. The shield formed of'fixed section 5! and movable section 53 covers the drum a binder or thelike may be applied to its outer face by spray head 86. When the layerreaches the under face of the drum it is contacted on its inner surfaceby the fluid jets issuing from nozzles 46. As thenozzle member 42 swingsback and forth in its oscillatory path, the jets force or peel the layerof fibers from the surface of the drum and lay the layer back and forthin a plurality of laminations or folds on conveyor 66. The jets may alsoapply a hinder or the like to the under surface of the layer, aspreviously described, and binder may also be applied by. oscillatingspray pipe illl. All or only selected ones of the binder applyingdevices may be employed, depending on the thickness of the layer formedon the drum, the character and amount of binder employed, and the like.Because of the coincidental forward movement of the conveyor, 2.continuous felt or blanket is formed thereon, the thickness of which iscontrolled by the speed of the conveyor relative to the binder, and todivide the blanket into batts or pads of commercial size, and the like.

As a specific example of the operation of the instant invention, whichhowever is not to be employed in a limiting sense, the drum is rotatedat a speed relative to the rate of fiber formation to form a layer about2' wide and V thick. The oscillations of nozzle member 42 are controlledby proper selection of cam 64 and the speed of the conveyor is regulatedrelatively to that of the drum to assemble a blanket on the conveyorabout 5 wide and 3" thick to meet the requirements for typical products.

Owing to the thin, loose characteristics of the layer built up on thedrum, the application of a binder or other treating material in themanner previously described provides substantially completedissemination of the binder throughout the layer,-which, in turn, whenthe layers are laid on the conveyor, results in substantially uniform Pdissemination throughout the final felt. The

treating material supplied to device 86, nozzle member 42 and/or spraypipe 90 may be of the conventional hinder or waterproofing materials,such as asphalts, drying oils, resins, waxes, or

other materials for similar purposes.

- Having thus described our invention in rather full detail, it will beunderstood that these details need not be strictly adhered to, but thatchanges and modifications will suggest themselves to one skilled in theart, all falling within the scope of the invention as defined by thesubjoined claims.

What we claim is:

1. In an apparatus having means for converting a molten material intofibers, a rotatable drum having an air-pervious fiber-collectingsurface, means to cause deposit of the fibers in the form of a thinlayer on said surface, means for rotating said drum, means beneath saiddrum to receive said layer, and oscillating means within said drum fordischarging a fluid jet through said surface to remove said layertherefrom, said lastnamed means being operable to lay said layer infolds on said receiving means.

2. In an apparatus having means for converting a molten material intofibers, a rotatable drum having an air-pervious fiber-collectingsurface, means to cause deposit of the fibers in the form of a thinlayer on said surface, means for rotating said drum, a conveyorextending in a generally parallel direction to the axis of said drum toreceive said layer, and oscillating means within said drum fordischarging a fluid Jet through said surface to remove said layer, saidlast-named means being operable to lay said layer in laterally extendingfolds on said conveyor.

3. In an apparatus having means for converting a molten. material intofibers, a rotatable dium having an air-pervious fiber-collectingsurface, means to cause deposit of the fibers in the form of a thinlayer on said surface, means for rotating said drum, means beneath saiddrum to receive said layer, and means to remove said layer and lay it infolds on said receiving means, said last-named means including a nozzlemember within said drum positioned to discharge fluid jets through saidsurface, and means for oscillating said nozzle member in an arcuatepath.

4. In an apparatus having means for converting a molten material intofibers, a rotatable drum having an air-pervious fiber-collectingsurface, means to cause depositof the fibers in the form of a thin layeron said surface, means for rotating said drum, a conveyor beneath thedrum and extending in a direction generally parallel to the axis of thedrum, means to drive said conveyor at'a controlled speed relative to therotation of said drum, and means to remove said layer and lay it infolds on said conveyon'said 7 last named means comprising a nozzlemember within said drum positioned to discharge fiuid Jets through saidsurface, and means for oscillating said nozzle member in an arcuatepath.

5. In an apparatus having means fcrconverting a molten material intofibers, a rotatable drum having an air-pervious fiber-collectingsurface, means to cause deposit of the fibers in the form of a thinlayer on said surface, means for rotating said drum, an air-perviousconveyor beneath said drum to receive said layer, suction means actingthrough said conveyor, and oscillating means within said drum fordischarging a fluid Jet through said surface to remove said layer, saidlast-named means being operable to lay said layer in folds on saidreceiving member.

8. Inan apparatus having means forconverting a molten material intofibers, a rotatable drum having an air-pervious fiber-collectingsurface, means to cause deposit of the fibers on said surface in theform of a thin layer, means for rotating said drum, an air-perviousconveyor located beneath said drum to receive said layer, suction meansacting through said conveyor, means to drive said conveyor at acontrolled speed relative to the rotation of said drum, and means toremove said layer and lay it in folds on said conveyor, said last namedmeans comprising a nozzle member within said drum positioned todischarge fluid Jets through said surface, and means for oscillatingsaid nozzle member in an arcuate path.

7. In a mineral wool apparatus having means for converting a moltenmaterial into fibers. a drum comprising an air-pervious surface having afiber-receiving area adjacent to said means, a suction device actingthrough said surface, means for rotating said drum, a conveyor beneathsaid drum extending in a direction generally parallel to the axis of thedrum, a nozzle means for blowing fluid jets through said surface abovesaid discharge fiuid jets through said surface above said conveyor toforce the layer from said surface, means for oscillating said nozzlemember in an arcuate path, and means for delivering a treating materialof the type of a binder or waterproofing media to said nozzle memberwhereby said treating material is applied to the inner face of saidlayer.

10. In a mineral wool apparatus having means for converting a moltenmaterial into fibers, a

rotatable drum having an air-pervious surface,

means to cause deposit of said fibers to form a thin layer on saidsurface, means for rotating said drum, receiving means below said drumto receive the layer therefrom, and a nozzle member for removing saidlayer from said drum and depositing it in folds on said receiving means,said nozzle member comprising a pipe located within said drum andextending axially thereof conveyor, said nozzle means being mounted foroscillatory movement, and means for oscillating said nozzle meansthrough an arcuate path substantially concentric with said drum.

8. In a mineral wool apparatus having means for converting a moltenmaterial into fibers, a fiber-collecting drum having an air-pervioussurface, means to cause deposit of the fibers on said surface in theform of a thin layer, means for rotating said drum, a conveyor beneathsaid drum, means for applying a treating material of the type ofa'binder or waterproofing media to the outer face of said layer on saiddrum, a nozzle member within said drum positioned to discharge fluidjets through said surface above said conveyor to force the layer fromsaid surface, and means for delivering a treating material of a type ofa hinder or waterproofing media to said nozzle member whereby treatingmaterial is applied to the inner face of said layer.

9. In a mineral wool apparatus having means for converting a moltingmaterial into fibers, a fiber-collecting drum having an air-pervioussurface, means to cause deposit of the fibers on said surface in theform of a thin layer, means for rotating said drum, a conveyor beneathsaid drum, means for applying a treating material of .the type of abinder or waterproofing media to the outer face of said layer on saiddrum, a nozzle member within said drum positioned to and having aplurality of nozzles positioned to direct fluid jets through saidsurface above said receiving means, an oscillatory arm carrying saidpipe, means for supplying a fluid under pressure to said pipe throughsaid arm, and means for oscillating said arm to move said pipe throughan arc to lay said fiber in folds back and' forth across said receivingmeans.

11. In an apparatus having means for converting a molten material intofibers, a movable fibercollecting means, means to cause deposit of thefibers on said collecting means in the form of a thin layer, means formoving said collecting means, a traveling receiving member adjacent saidcollecting means, and jet means oscillating in a path adjacent thesurface of the collecting means for removing said layer from thecollecting means and for'directly laying it in laterally extending,overlapping folds on said receiving member.

12. In a mineral wool apparatus having means for converting moltenmaterial into fibers, a fiber-collecting means, means to cause depositof the fibers on said collecting means in the form of a thin layer, jetmeans oscillating in a path adjacent the surface of the fiber-collectingmeans for removing the layer from the collecting means and for directlylaying it in folds on a receiving member, and means for applying atreating material of the type of a hinder or waterproofing media to bothfaces of the material prior to its deposit on said receiving member.

HAROLD T. COSS. EDWARD POWELL.

REFERENCES CITED =The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Date Von Pazsiczky Nov. 2, 1943

